U.S. patent number 7,836,663 [Application Number 11/350,741] was granted by the patent office on 2010-11-23 for poly-bonded framed panels.
This patent grant is currently assigned to Platinum Advanced Technologies, Inc.. Invention is credited to William J. Harrington, Fred L. Solomon.
United States Patent |
7,836,663 |
Solomon , et al. |
November 23, 2010 |
Poly-bonded framed panels
Abstract
A one layer building panel derives its structural integrity from
a foam forming the layer that bonds to horizontal and vertical stud
members with a mesh material disposed therein. The vertical members
can be provided at the edges of the building panel. The horizontal
members can be provided at the edges of the building panel and
together with the vertical member form a peripheral frame for the
building panel. The foam is bonded to the horizontal and vertical
stud members using above ambient temperatures and pressures. A mesh
can be provided within the foam. A fiber reinforced layer can be
provided on the interior and/or exterior surfaces of the foam.
Building panels can be connected to one another to construct a
building wall and ceiling using stud members having an interlocking
capabilities. The building panels can be inserted into tracks
secured to a floor using anchors.
Inventors: |
Solomon; Fred L. (Gulfport,
FL), Harrington; William J. (Munster, IN) |
Assignee: |
Platinum Advanced Technologies,
Inc. (St. Petersburg, FL)
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Family
ID: |
37741310 |
Appl.
No.: |
11/350,741 |
Filed: |
February 10, 2006 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20070033890 A1 |
Feb 15, 2007 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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11201156 |
Aug 11, 2005 |
7621101 |
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Current U.S.
Class: |
52/782.1;
52/784.15 |
Current CPC
Class: |
E04C
2/296 (20130101); E04C 2/384 (20130101) |
Current International
Class: |
E04C
2/00 (20060101) |
Field of
Search: |
;52/309,309.4,309.14,309.15,799.1,784.14,463
;428/304.4,44,317.9,306.6,308.4,297.4,297.7
;442/30,55,221,226,315,370,374 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
Non-Final Office action dated Jan. 11, 2007 received in U.S. Appl.
No. 11/201,156. cited by other .
Notice of Allowance dated Oct. 1, 2008 received in U.S. Appl. No.
11/201,156. cited by other .
Supplemental Notice of Allowability dated Feb. 6, 2009 received in
U.S. Appl. No. 11/201,156. cited by other.
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Primary Examiner: Chilcot, Jr.; Richard E
Assistant Examiner: Laux; Jessica
Attorney, Agent or Firm: Hanify & King, P.C.
Parent Case Text
CROSS-REFERENCES TO RELATED APPLICATIONS
This is a continuation-in-part application taking priority from
Ser. No. 11/201,156 filed on Aug. 11, 2005 now U.S. Pat. No.
7,621,101.
Claims
We claim:
1. A building panel including studs used in construction,
comprising: a peripheral frame configured with the studs, wherein
the studs include a top horizontal stud member, a bottom horizontal
stud member, a left vertical stud member, and aright vertical stud
member, wherein a first end portion of the top horizontal stud
member joins to a first end portion of left vertical stud member, a
second end of the top horizontal stud member joins to a first end
portion of right vertical stud member, a first end portion of the
bottom horizontal stud member joins to a second end portion of left
vertical stud member, and a second end portion of the bottom
horizontal stud member joins to a second end of the right vertical
stud member; a foam formed at least within the peripheral frame,
wherein the foam is bonded to the peripheral frame, and wherein the
foam consists essentially of a material selected from the group
consisting of polystyrene, polyurethane, polyurea, and
polyisocyanurate; and a woven material disposed on only a first
side of the foam, wherein the woven material consists essentially
of a fiber stitch bonded together.
2. The building panel of claim 1, wherein the structural integrity
of the building panel is derived from the bonding of the foam to
the peripheral frame.
3. The building panel of claim 1, wherein the foam is a
thermoplastic or a thermoset polyurethane.
4. The building panel of claim 1, wherein the top horizontal stud
member, the bottom horizontal stud member, the right vertical stud
member, and the left vertical stud member are constructed from one
of: metal, aluminum, wood, and plastic.
5. The building panel of claim 1, wherein the top horizontal stud
member, the bottom horizontal stud member, the right vertical stud
member, and the left vertical stud member are configured as one of:
a convention stud, and a c-shaped stud.
6. The building panel of claim 1, wherein the first side of the
foam defines an exterior surface of the building panel.
7. The building panel of claim 6, further comprising a mesh
provided within the foam.
8. The building panel of claim 7, wherein the foam and the mesh
extends to the outer boundary of the peripheral frame.
9. The building panel of claim 6, wherein a second side of the foam
defines an interior surface of the building panel.
10. The building panel of claim 1, wherein the foam has a thickness
substantially equivalent to a thickness of studs.
11. The building panel of claim 1, wherein the foam has a thickness
to substantially cover the studs.
12. The building panel of claim 1, wherein the fiber is selected
from the group consisting of Fiberglass, Aramid, Carbon and Natural
fibers.
13. A building panel comprising: a peripheral frame configured with
a plurality of studs, wherein the plurality of studs comprise: a
top horizontal stud member; a bottom horizontal stud member; a left
vertical stud member; and a right vertical stud member, wherein a
first end portion of the top horizontal stud member joins to a
first end portion of left vertical stud member, a second end of the
top horizontal stud member joins to a first end portion of right
vertical stud member, a first end portion of the bottom horizontal
stud member joins to a second end portion of left vertical stud
member, and a second end portion of the bottom horizontal stud
member joins to a second end of the right vertical stud member; a
foam insert at least within the peripheral frame comprising: a
foamed layer having a front side and a back side and formed from a
material consisting essentially of polystyrene, polyurethane,
polyurea, and polyisocyanurate; and a woven material disposed onto
the front side of the foamed layer to define an exterior surface of
the building panel, wherein the woven material consists essentially
of a fiber stitch bonded together.
14. The building panel of claim 13, wherein the material is a
thermoplastic or thermoset polyurethane.
15. The building panel of claim 13, wherein the fiber is selected
from the group consisting of Fiberglass, Aramid, Carbon and Natural
fibers.
16. A building panel comprising: a peripheral frame configured with
the studs, wherein the studs include a top horizontal stud member,
a bottom horizontal stud member, a left vertical stud member, and a
right vertical stud member, wherein a first end portion of the top
horizontal stud member joins to a first end portion of left
vertical stud member, a second end of the top horizontal stud
member joins to a first end portion of right vertical stud member,
a first end portion of the bottom horizontal stud member joins to a
second end portion of left vertical stud member, and a second end
portion of the bottom horizontal stud member joins to a second end
of the right vertical stud member; a polyurethane foam formed at
least within the peripheral frame, wherein the foam is bonded to
the peripheral frame; and a woven material disposed on a first side
of the polyurethane foam, wherein the woven material consists
essentially of fiber stitch bonded together.
17. A building panel comprising: a peripheral frame configured with
the studs, wherein the studs include a top horizontal stud member,
a bottom horizontal stud member, a left vertical stud member, and a
right vertical stud member, wherein a first end portion of the top
horizontal stud member joins to a first end portion of left
vertical stud member, a second end of the top horizontal stud
member joins to a first end portion of right vertical stud member,
a first end portion of the bottom horizontal stud member joins to a
second end portion of left vertical stud member, and a second end
portion of the bottom horizontal stud member joins to a second end
of the right vertical stud member; a polyurethane foam formed at
least within the peripheral frame, wherein the foam is bonded to
the peripheral frame; and a woven material disposed on only a first
side of the polyurethane foam, wherein the woven material consists
essentially of fiber stitch bonded together and selected from the
group consisting of Fiberglass, Aramid, Carbon and Natural fibers.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a building panel, method of
fabricating the building panel, and method of constructing a build
employing the building panel. More particularly, the present
invention relates to a framed building panel, method of fabricating
the framed building panel, and method of constructing a build
employing the building panel, wherein the framed building panel has
increase structural integrity and is operable to construct a wall,
roof, floor, ceiling, room, and building.
2. Description of the Prior Art
The construction industry is continuously attempting to find ways
to reduce the time, cost, and labor associated with the
construction of a structure, such as a building, wall, room, floor,
ceiling and roof. Techniques used to reduce the time, cost, and
labor associated with the construction of a structure includes
prefabrication of various portions of a structure. Once the portion
of the structure is fabricated, it is then transported to the
construction site for placement in its intended location. One
problem with such techniques is that the prefabricated portion of
the structure is constructed with conventional materials using the
techniques that would be used on the construction site. Another
problem with these techniques is that the prefabricated portion is
subject to damage during its transportation to the construction
site.
These techniques typically also require that the structural
integrity of the prefabricated portion of the building is derived
solely from the frame of the prefabricated portion. In some
instances, the structural integrity of the prefabricated portion of
the building and the building itself is further derived from the
specific way a prefabricated portion needs to be assembled with
another portion of the building using connections, fasteners, and
other coupling mechanisms specific to using the prefabricated
portion.
Accordingly, there is a need for a building panel having structural
integrity, a method of fabricating the building panel having
structural integrity, and method of constructing a building
employing the building panel. There is a need for the building
panel having structural integrity and the method of fabricating the
building panel having structural integrity, where the structural
integrity is derived from the bonding of the foam to vertically and
horizontally aligned stud members. There is a need for the
vertically and horizontally aligned studs to form a frame. There is
a need for the foam to define an interior side of the building
panel and an exterior side of the building panel. There is a need
for the building panel having structural integrity to couple to
another building panel having structural integrity. There is a need
for the building panel to interlock with an adjacent building panel
employing an interlocking stud. There is a need for the building
panel to be held in an upright position employing a track secured
to a floor, such as with an anchor.
SUMMARY OF THE INVENTION
According to an embodiment of the present invention, a building
panel having structural integrity, a method of fabricating the
building panel having structural integrity, and method of
constructing a building employing the building panel are provided.
The building panel is a one layer building panel that derives its
structural integrity from a foam forming the layer that bonds to
horizontal and vertical stud members. The vertical members can be
provided at the edges of the building panel. The horizontal members
can be provided at the edges of the building panel and together
with the vertical member form a peripheral frame for the building
panel. The foam is bonded to the horizontal and vertical stud
members using above ambient temperatures and pressures. Building
panels can be coupled to one another to construct a structure, such
as a room, floor, level and roof, using vertical members at the
edges having an interlocking capabilities. One or more building
panels can be inserted into one or more tracks secured to a floor
to hold the one or more building panels in an upright position.
According to an embodiment of the present invention, a building
panel having structural integrity is provided. The building panel
includes a peripheral frame having a top horizontal stud member, a
bottom horizontal stud member, a left vertical stud member, and a
right vertical stud member. A first end portion of the top
horizontal stud member joins to a first end portion of left
vertical stud member, a second end of the top horizontal stud
member joins to a first end portion of right vertical stud member,
a first end portion of the bottom horizontal stud member joins to a
second end portion of left vertical stud member, and a second end
portion of the bottom horizontal stud member joins to a second end
of the right vertical stud member. A foam is formed at least within
the peripheral frame, wherein the foam is bonded to the peripheral
frame. A first side of the foam defines an exterior surface of the
building panel, and a second side of the foam defines an interior
surface of the building panel. Mesh is provided within the
foam.
In an embodiment of the present invention, the structural integrity
of the building panel is derived from the bonding of the foam to
the peripheral frame.
In an embodiment of the present invention, the foam comprises a
thermoplastic material or a thermoset material.
In an embodiment of the present invention, the top horizontal stud
member, the bottom horizontal stud member, the right vertical stud
member, and the left vertical stud member are constructed from one
of: metal, aluminum, wood, and plastic.
In an embodiment of the present invention, the top horizontal stud
member, the bottom horizontal stud member, the right vertical stud
member, and the left vertical stud member are configured as one of:
a convention stud, a c-shaped stud, and an interlocking stud.
In an embodiment of the present invention, a first side of the foam
defines an exterior surface of the building panel and a second side
of the foam defines an interior surface of the building panel.
In an embodiment of the present invention, a fiber reinforced
surface layer is applied to the exterior surface of the building
panel.
In an embodiment of the present invention, a fiber reinforced
surface layer is applied to the interior of the building panel.
In an embodiment of the present invention, the foam and the mesh
extends to the outer boundary of the peripheral frame.
In an embodiment of the present invention, at least one of the
right vertical stud member, the left vertical stud member, top
horizontal stud member, and bottom vertical stud member is an
interlocking stud operable to interlock with an interlocking stud
of an adjacent structural component.
According to an embodiment of the present invention, an
interlocking stud to guide to edge of a first building panel into a
receiving edge of another building is provided.
In an embodiment of the present invention, a structural component
couples to the interlocking stud within the first side wall and
second side wall.
In an embodiment of the present invention, the interlocking stud is
operable to interlock with another interlocking stud.
According to an embodiment of the present invention, an improved
modular building is provided. The building includes a first set of
building panels defining a perimeter of the modular building,
wherein each of the building panels include a peripheral frame
having a top horizontal stud member, a bottom horizontal stud
member, a left vertical stud member, and a right vertical stud
member. A first end portion of the top horizontal stud member joins
to a first end portion of left vertical stud member. A second end
of the top horizontal stud member joins to a first end portion of
right vertical stud member. A first end portion of the bottom
horizontal stud member joins to a second end portion of left
vertical stud member. A second end portion of the bottom horizontal
stud member joins to a second end of the right vertical stud
member. A foam formed at least within the peripheral frame is
bonded to the peripheral frame. A first side of the foam defines an
exterior surface of the building panel, and a second side of the
foam defines an interior surface of the building panel. Each of the
building panels configured with an interlocking stud as the left
vertical stud member and the right vertical stud member for
interlocking with an adjacent building panel configured with an
interlocking stud as the left vertical stud member and the right
vertical stud member. A covering is supported by, and secured to,
the set of building panels.
In an embodiment of the present invention, the covering is
constructed from a second set of building panels.
In an embodiment of the present invention, tracks includes a base
portion, a first track sidewall, and a second track sidewall and is
anchored to a foundation of the modular building with a set of
anchors including, but not limited to, anchor bolts or other
similar methods.
In an embodiment of the present invention, an anchor is inserted
through a hole receptive in the base portion of a track into the
foundation and a top portion of the anchor engages the base portion
of the track and the base portion of the track engages the
foundation.
According to an embodiment of the present invention, A system for
securing a wall of a building to a foundation is provided. The
system includes a track including a base portion, a first track
sidewall, and a second track sidewall and an anchor each having a
J-shape configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
The above described features and advantages of the present
invention will be more fully appreciated with reference to the
detailed description and appended figures in which:
FIGS. 1A-1B depict exemplary diagrams of a building panel having
structural integrity according to an embodiment of the present
invention;
FIG. 1C depicts an exemplary top view of a c-shaped stud with foam
and mesh according to an embodiment of the present invention;
FIG. 2 depicts an exemplary diagram of a building panel with a
diagonal stud member having structural integrity according to an
embodiment of the present invention;
FIG. 3 depicts an exemplary diagram of a building panel with an
inner vertical stud member having structural integrity according to
an embodiment of the present invention;
FIG. 4 depicts an exemplary diagram of an anchor and track
according to an embodiment of the present invention;
FIG. 5 depicts an exemplary flow chart of a method for constructing
a structure using a set of building panels according to an
embodiment of the present invention; and
FIG. 6 depicts an exemplary flow chart of a method of fabricating
the building panel shown in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is now described more fully hereinafter with
reference to the accompanying drawings that show embodiments of the
present invention. The present invention, however, may be embodied
in many different forms and should not be construed as limited to
embodiments set forth herein. Appropriately, these embodiments are
provided so that this disclosure will be thorough and complete, and
will fully convey the scope of the present invention.
According to an embodiment of the present invention, a building
panel having structural integrity, a method of fabricating the
building panel having structural integrity and method of
constructing a building employing the building panel are provided.
The building panel is a one layer building panel that derives its
structural integrity from a foam forming the layer that bonds to
horizontal and vertical stud members. The vertical stud members can
be provided at the edges of the building panel. The horizontal stud
members can be provided at the edges of the building panel and
together with the vertical stud member form a peripheral frame for
the building panel. The foam is bonded to the horizontal and
vertical stud members using temperatures and pressures above
ambient. Building panels can be coupled to one another to construct
a structure, such as a room, floor, level and roof, using vertical
and horizontal stud members at the edges having an interlocking
capabilities. One or more building panels can be inserted into one
or more tracks secured to a floor to hold the one or more building
panels in an upright position.
Exemplary diagrams of a building panel having structural integrity
according to an embodiment of the present invention are shown in
FIGS. 1A-1B. In the embodiment of FIG. 1A, building panel 100
includes a top horizontal stud member 102, a bottom horizontal stud
member 104, a right vertical stud member 106, a left vertical stud
member 108, and a foam member 110. The building panel of FIG. 1A
includes an exterior panel side 112, an interior panel side 114,
and a mesh member 116 positioned within foam member 110 as shown in
FIG. 1B. In the FIG. 1A embodiment of the present invention, the
top horizontal stud member 102, bottom horizontal stud member 104,
right vertical stud member 106, and left vertical stud member 108
can be constructed from one of metal, aluminum, wood and plastic.
In an embodiment of the present invention, a stud member, such as
top horizontal stud member 102, bottom horizontal stud member 104,
right vertical stud member 106, and/or left vertical stud member
108, can be configured as a conventional stud, a c-shaped stud, an
interlocking stud, or the like. In an embodiment of the present
invention, the foam member 110 forms around the c-shaped stud
members to provide increase structural integrity and mesh member
116 couples to c-shaped stud member as shown in FIG. 1C. In an
embodiment of the present invention, the mesh member 116 is
provided within the foam member 110. In an embodiment of the
present invention, the mesh can span the extent of the foam member
110 and couple to each of the top horizontal stud member 102,
bottom horizontal stud member 104, right vertical stud member 106,
and left vertical stud member 108. In an embodiment of the present
invention, a set of mesh members can be provided within the foam
member 110 and extend from the top horizontal stud member 102 to
the bottom horizontal stud member 104. In an embodiment of the
present invention, a set of mesh members can be provided within the
foam member 110 and extend from the left vertical stud member 108
to the right vertical stud member 106.
The mesh member 116 can be configured from materials including, but
not limited to, aluminum, steal, copper, and plastic. In an
embodiment of the present invention, the mesh size can be from 2
Mesh to 325 Mesh which means the number of meshes per lineal inch
of material. In an embodiment of the present invention, the mesh
size can be 5 Mesh to 300 Mesh. In an embodiment of the present
invention gauge of the mesh can be from 50 gauge to 10 gauge. In
another embodiment, the mesh has a gauge ranging from 40 to 10. In
an embodiment of the present invention, the mesh has a gauge
ranging from 30 to 15.
In an embodiment of the present invention, a surface of foam member
110 can be provided with a fiber reinforced surface layer 118 as
shown in FIG. 1C. The fiber can be made from any material that
strengthens the impact level of the panel member 100. The material
can be, but is not limited to, Fiberglass, Aramid, Carbon and
Natural fibers. In an embodiment of the present invention, the
weight per square yard of the fiber can range from 12 oz. to 300
oz. In an embodiment of the present invention, the weight per
square yard of the fiber can range from 12 oz. to 100 oz. In an
embodiment of the present invention, the weight per square yard of
the fiber can range from 75 oz. to 200 oz. In an embodiment of the
present invention, the weight per square yard of the fiber can
range from 125 oz. to 300 oz. The orientation of the fibers with
respect to the longitudinal axis of the panel surface can be 0,
+/-5, +/-10, +/-15, +/-30, +/-45, +/-60 and +/-90 degrees or any
angle in between. The fiber layers can be either stitch bonded or
woven together to form multiple ply cloths 120, as shown in FIG.
1C, which are utilized in the production of the panels.
In the FIG. 1A embodiment of the present invention, top horizontal
stud member 102 and bottom horizontal stud member 104 are axially
aligned and positioned at the upper and lower periphery of building
panel 100 to form the top and bottom of building panel 100. In an
embodiment of the present invention, top horizontal stud member 102
and bottom horizontal stud member 104 are axially align and
positioned at a predetermined distance from one another. In the
FIG. 1A embodiment of the present invention, right vertical stud
member 106 and left vertical stud member 108 are axially aligned
and positioned at the left and right periphery of building panel
100 to form the left side and right side of building panel 100. In
an embodiment of the present invention, left vertical stud member
108 and right vertical stud member 106 are axially aligned and
positioned at a predetermined distance from one another. In an
embodiment of the present invention, the vertical stud members 106
and 108 extend the height of the building panel 100 and the
horizontal stud members 102 and 104 extend the length of the
building panel 100. In an embodiment of the present invention, the
vertical stud members 106 and 108 of building panel 100 are
configured to interlock with a vertical stud member of an adjacent
building panel 100 to form a wall or room. In an embodiment of the
present invention, the horizontal stud members 102 and 104 are
configured to interlock with the interlocking stud members of
building panels used to form a ceiling, roof, or floor of a
structure. The building panel can be secured to a floor member to
hold the building panel in an upright position by methods
including, but not limited to, slots in the foundation or direct
fixation with screws, welds or adhesives.
In the FIG. 1A embodiment of the present invention, the top
horizontal stud member 102, bottom horizontal stud member 104,
right vertical stud member 106, and left vertical stud member 108
form a frame around panel member 110. In the FIG. 1A embodiment of
the present invention, a first end portion of the top horizontal
stud member 102 squarely abuts a first end portion of left vertical
stud member 108. In the FIG. 1A embodiment of the present
invention, a second end of the top horizontal stud member 102
squarely abuts a first end portion of right vertical stud member
106. In the FIG. 1A embodiment of the present invention, a first
end portion of the bottom horizontal stud member 104 squarely abuts
a second end portion of left vertical stud member 108. In the FIG.
1A embodiment of the present invention, a second end portion of the
bottom horizontal stud member 104 squarely abuts a second end of
right vertical stud member 106. In an embodiment of the present
invention, the members can be coupled, such as by screws, welding,
adhesive and bolts, at the points of abutment to further provide
structural integrity.
In the FIG. 1A embodiment of the present invention, panel member
110 extends and bonds to the inner side of each of the top
horizontal stud member 102, bottom horizontal stud member 104,
right vertical stud member 106, and left vertical stud member 108.
In the FIG. 1A embodiment of the present invention, the thickness
of the panel member 110 is substantially the same as the width of
the top horizontal stud member 102, bottom horizontal stud member
104, right vertical stud member 106, and left vertical stud member
108. The front side and back side of the foam member 110 defines
the exterior and interior of building panel 100. In an embodiment
of the present invention, building panel 100 conforms to chapter 26
of the International building code for requirements including, but
not limited to, flame spread and smoke spread.
In an embodiment of the present invention, panel member 110 extends
to the outer side of each of the top horizontal stud member 102,
bottom horizontal stud member 104, right vertical stud member 106,
and left vertical stud member 108 and bonds to the back, front, and
inner sides of each of the top horizontal stud member 102, bottom
horizontal stud member 104, right vertical stud member 106, and
left vertical stud member 108. In an embodiment of the present
invention, the panel member 110 thickness extends beyond the width
of each of the top horizontal stud member 102, bottom horizontal
stud member 104, right vertical stud member 106, and left vertical
stud member 108. In an embodiment of the present invention, the
front side and back side of the foam member 110 defines the
exterior and interior of building panel 100 as well as the exterior
and interior of a wall, roof, or ceiling for a structure
constructed with building panel 100.
An exemplary embodiment of the building panel 100 of FIGS. 1A-1B is
shown in FIG. 2 with a diagonal stud member. In the FIG. 2
embodiment of the present invention, diagonal stud member 202 can
be constructed from one of metal, aluminum, wood and plastic. In
the FIG. 2 embodiment of the present invention, a first end portion
of the diagonal stud member 202 abuts to a second end portion of
the top horizontal stud member 102 and a first end portion of right
vertical stud member 106. In the FIG. 2 embodiment of the present
invention, a second end portion of the diagonal stud member 202
abuts a first end portion of the bottom horizontal stud member 104
squarely and second end portion of left vertical stud member 108.
In the FIG. 2 embodiment of the present invention, panel member 110
extends and bonds to the inner side of each of the top horizontal
stud member 102, bottom horizontal stud member 104, right vertical
stud member 106, and left vertical stud member 108 as well as the
right and left side of diagonal stud member 202. In an embodiment
of the present invention, the members can be coupled at the points
of abutment to further provide structural integrity.
An exemplary embodiment of the building panel 100 of FIGS. 1A-1B is
shown in FIG. 3 with an inner vertical stud member. In the FIG. 3
embodiment of the present invention, an inner vertical stud member
302 can be constructed from one of metal, aluminum, wood and
plastic. In the FIG. 3 embodiment of the present invention, a fist
end portion of an inner vertical stud member 302 squarely abuts the
top horizontal stud member 102 and a second end of the inner
vertical stud member 302 squarely abut the bottom horizontal stud
member 104. In the FIG. 3 embodiment of the present invention,
panel member 110 extends and bonds to the inner side of each of the
top horizontal stud member 102, bottom horizontal stud member 104,
right vertical stud member 106, and left vertical stud member 108
as well as the right and left side of inner vertical stud member
106. In an embodiment of the present invention, the members can be
coupled at the points of abutment to further provide structural
integrity. In an embodiment of the present invention, inner stud
members can be configured to define openings for doors, windows,
and the like.
An exemplary side view of an anchor and track is shown in FIG. 4.
In the FIG. 4 embodiment of the present invention, the track 400
has a C-shaped configuration having a base and two sidewalls
projecting upward from the base, which can be secured to a floor at
the side of base opposite the sidewalls using one or more anchors.
In an embodiment of the present invention, the track 400 can be
used to hold one or more wall structures, such as a building panel
100, in an upright position between the sidewalls. The track 400
can be constructed from one of metal, aluminum, and the like. In an
embodiment of the present invention, the track can be secured to a
floor using an anchor 402 including, but not limited to, one or a
combination of screws, bolts, welds, anchors, adhesive, and the
like. The anchor 402 can be constructed from one of metal, steel,
and the like. In an embodiment of the present invention, the floor
is pre-dried concrete and the base of the track 400 meets with a
pre-dried concrete floor. Once the concrete dries, the track 400
and anchor are securely fastened to the concrete floor.
An exemplary flow chart of a method of constructing a structure
using the building panels, anchor and track, and interlocking stud
member is shown in FIG. 5. The type of structure includes, but are
not limited to, a wall, roof, room, home, commercial building,
strip mall, cold storage facility, and apartment building. The
method begins with step 500. In step 500, a set of tracks is
positioned in a configuration to define the outer boundaries of a
building. In step, 502, anchors are inserted through holes in the
tracks and into the floor that the tracks sit on. In an embodiment
of the present invention, the floor is concrete. In step 504, the
walls of the structure are constructed. In the FIG. 5 embodiment of
the present invention, construction of a wall includes, inserting a
set of building panels within the sidewalls of the track and
interlocking the interlocking stud members of adjacent building
panels. To inserting a building panel within the sidewalls of the
track, the building panel can be lifted over the sidewalls of the
track. Interlocking the interlocking stud of the building panel to
the interlocking stud of an adjacent building panel is performed
prior to inserting the building panel into the track. The
interlocking of interlocking studs and insertion of interlocked
building panels into the track secures the interlocked building
panels to one another in an upright position. A ceiling constructed
from the building panels can be secured to a wall constructed of
the ceiling panels employing an eave lock, wherein the eave lock
has a base portion and a pair of sidewall, each sidewall being
angled away from the base portion.
An exemplary flow chart of a method of fabricating the building
panel of FIG. 1 is shown in FIG. 6. The method begins in step 600.
In step 600, a peripheral frame of stud members is placed in a mold
press. In an embodiment of the present invention, the mold press
includes an enclosure having a top panel, sidewalls and a bottom
panel. In an embodiment of the present invention, a mesh is coupled
to the peripheral frame. In an embodiment of the present invention,
a mesh is suspended within the peripheral frame. In an embodiment
of the present invention, dry fiber 120 as shown in FIG. 1C is laid
on the bottom panel and/or provided on the top panel of the mold
press. Once the foam is injected into the mold press the fiber is
impregnated with the foam.
In step 602, the top panel is placed on, and secured to the
sidewalls. In an embodiment of the present invention, the top panel
is secured to the sidewalls with sufficient strength to sustain
pressures achieved by the mold press. In one embodiment, the studs
and/or mesh can be surface treated for improved bonding. Surface
treatment can be effected by any of the several techniques known in
the art, such as corona discharge, plasma treatment, ozone
treatment, sand blasting, brush tumbling, and the like. Preferably,
surface treatment is effected by grinding with an abrasive wheel.
As will be appreciated by those of ordinary skill in the art, the
effect of the surface treatment can vary based on the type of
material used to fabricate the stud and/or mesh. For example, a
metal stud can be subjected to sand blasting in order to increase
the adhesion between the metal stud and the foam material.
In an alternate embodiment, a metal stud can be pretreated with a
plasma thermal spray coating thus taking advantage of the ability
of plasma technology to excite gas atoms and molecules into
transient and nonequilibrium conditions. An enclosed vacuum chamber
can be used to excite the gas molecules by subjecting the gas
mixture to an electrified field of radio frequency (rf) energy. In
the alternative, the plasma technology can be performed under
atmospheric pressure and ambient temperature, without the use of
vacuum equipment. The oxygen functionalities created on the
surfaces are chemically reactive and permanent and allow the foam
material to form a covalent bond to the modified surface.
In step 604, a foam is injected and distributed consistently into
the mold press. In an embodiment of the present invention, the foam
is injected within, and bonded to, the peripheral frame. In an
embodiment of the present invention, the foam is injected within,
over, and bonded to, the frame. In an embodiment of the present
invention, the foam has a thickness substantial equivalent to the
thickness of the stud members of the peripheral frame. In an
embodiment of the present invention, the foam has a thickness to
substantially cover the stud members of the peripheral frame.
In the FIG. 6 embodiment of the present invention, the press can be
maintained above-ambient pressure, where the pressure is directly
related to the density of the foam. In an embodiment of the present
invention, the density of the foam can be based on the specific
application that the building panel is going to be used. Any
suitable temperature and pressure can be provided that allows the
reaction to proceed. For example, the temperature may range from
about 32.degree. F. to about 180.degree. F. In one embodiment, the
reaction temperature is about 75.degree. F. to about 170.degree. F.
In another embodiment, the reaction occurs at a temperature of
about 75.degree. F. to about 150.degree. F. In yet another
embodiment, the reaction occurs at a temperature of about
80.degree. F. to about 85.degree. F. The pressure may range from
about 1 psi to about 15 psi. In one embodiment of the present
invention, the pressure is about 3 psi to about 10 psi. In another
embodiment of the present invention, the reaction occurs under a
pressure of about 5 psi to about 7 psi.
The foam can be any suitable foam material that is capable of being
injected and distributed consistently within the peripheral frame.
For example, the foam material may be a thermoset material or a
thermoplastic material. The foam may include, but is not limited
to, polystyrene, polyurethane, polyurea, polyisocyanurate, and the
like. In one embodiment, the material is a molded expanded
polystyrene foam. In another embodiment, the material is an
extruded expanded polystyrene foam.
In still another embodiment, polyurethane foam is used. The
polyurethane foam may be a single-component polyurethane, where the
main components (isocyanate and a hydroxy-terminated component) are
stored together as a blended mix, accompanied by a blowing agent in
liquid form, and catalyzed to cure when exposed to moisture in the
air. On release from their pressurized container, the two main
components react chemically, and the heat from this reaction causes
the blowing agent to convert into a gas and expand to form the
cellular structure of the foam. When the reaction is complete, the
gas is trapped within the material. In two-component polyurethane,
the same two main ingredients and appropriate catalysts are kept
apart until application. The chemical reaction when they are
combined is much faster than with one-component foam. Curing is
chemical, requires no air or moisture, and is independent of the
surrounding environment. As an alternative, polyiscyanurate foam
may be used for improved fire-resistance and higher R-values as
compared to polyurethane foam.
In yet another embodiment, the foam material includes polyurea
linkages and may be prepared by reacting an isocyanate with an
amine-terminated component. Whether the foam includes urethane or
urethane linkages, the foam may be the result of a one-shot method
or a prepolymer method. Those of ordinary skill in the art will
appreciate that the different methods have advantages and
disadvantages depending on the application.
Any isocyanate available to one of ordinary skill in the art is
suitable for use according to the invention. Isocyanates for use
with the present invention include aliphatic, cycloaliphatic,
araliphatic, aromatic, any derivatives thereof, and combinations of
these compounds having two or more isocyanate (NCO) groups per
molecule. Suitable isocyanate-containing components include
diisocyanates having the generic structure:
O.dbd.C.dbd.N--R--N.dbd.C.dbd.O, where R is preferably a cyclic,
aromatic, or linear or branched hydrocarbon moiety containing from
about 1 to about 20 carbon atoms.
Suitable hydroxy-terminated components include, but are not limited
to, polyols including polyether polyols, polycaprolactone polyols,
polyester polyols, polycarbonate polyols, hydrocarbon polyols, and
mixtures thereof. Both saturated and unsaturated polyols are
suitable for use with the present invention. Non-limiting examples
of amine-terminated compounds for use with the present invention
include amine-terminated hydrocarbons, amine-terminated polyethers,
amine-terminated polyesters, amine-terminated polycarbonates,
amine-terminated polycaprolactones, and mixtures thereof. The
amine-terminated segments may be in the form of a primary amine
(NH.sub.2) or a secondary amine (NHR).
If the prepolymer method is used to form a polyurethane or
polyurea-based material, the curing agent may include
hydroxy-terminated curing agents, amine-terminated curing agents,
and mixtures thereof. For example, any of the hydroxy-terminated
compounds or amine-terminated compounds discussed above are also
suitable for use as a curative.
As known to those of ordinary skill in the art, aliphatic or
saturated components, i.e., components that do not include C.dbd.C
or aromatic rings, produce foam materials that are less susceptible
to ultraviolet light. As such, in one embodiment (when applicable),
the foam includes only aliphatic components to result in a
non-yellowing product. This embodiment is especially useful when
the panels are intended to be left unpainted once installed.
Foaming of the material of the invention may occur through the
addition of at least one physical or chemical blowing or foaming
agent. Suitable blowing or foaming agents include, but are not
limited to, organic blowing agents, such as azobisformamide;
azobisisobutyronitrile; diazoaminobenzene;
N,N-dimethyl-N,N-dinitrosoterephthalamide;
N,N-dinitrosopentamethylene-tetramine; benzenesulfonyl-hydrazide;
benzene-1,3-disulfonyl hydrazide; diphenylsulfon-3-3, disulfonyl
hydrazide; 4,4'-oxybis benzene sulfonyl hydrazide; p-toluene
sulfonyl semicarbizide; barium azodicarboxylate; butylamine
nitrile; nitroureas; trihydrazino triazine; phenyl-methyl-uranthan;
p-sulfonhydrazide; peroxides; and inorganic blowing agents such as
ammonium bicarbonate and sodium bicarbonate.
In another embodiment, the material is foamed forcing a pressurized
gas, such as nitrogen or carbon dioxide, into the polymerizing
mixture. In another embodiment, the material is foamed by blending
microspheres with the composition either during or before the
molding process. Polymeric, ceramic, metal, and glass microspheres
are useful in the invention, and may be solid or hollow and filled
or unfilled.
The foamed material may be closed-cell or open-cell, however, as
known to those of ordinary skill in the art, a closed-cell foam
material forms a hydrophobic top skin. As such, if the material of
the invention is initially an open-cell foam, a subsequent sealant
is preferred to add hydrophobicity to the cured material.
In step 606, the top panel of the mold press is removed. In step
708, the building panel is removed from the mold press.
While specific embodiments of the present invention have been
illustrated and described, it will be understood by those having
ordinary skill in the art that changes can be made to those
embodiments without departing from the spirit and scope of the
invention.
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